Simulated shake shingle

ABSTRACT

An artificial shake type shingle is comprised of a molded composite of wood or cellulose particles and ground-up recycled polyvinyl chloride (PVC) particles. The PVC particles are preferably formed from recycled water or garden hose, preferably those with reinforcing fibers therein, which composition helps to attain a strong building material product.

CROSS-REFERENCE OF RELATED APPLICATION

This application is a continuation-in-part of U.S. patent applicationSer. No. 08/394,371 filed Feb. 24, 1995, now U.S. Pat. No. 5,635,125.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to simulated roofing shingles and, moreparticularly, an improved interlocking simulated shingle constructionmade from recycled materials.

2. Background Art

For many years wood, shingle, shake, and ceramic or clay tile roofinghas been used for the obvious purpose of sealing construction againstrain and other weather elements. With shake shingles, in particular,their rough appearance forms pleasing patterns that give themconsiderable decorative appeal and have become the standard and requiredroofing material in many residential areas. However, in time wood,typically cedar, shakes deteriorate because of insect infestation,rotting, splitting, cracking, warping, thermal expansion and absorptionof moisture, thereby decreasing their usefulness and decorative aspects.In addition, the cost of cedar shakes has substantially increased.

Various types of simulated shingles have been taught and patented assubstitutes for wood shakes. In many cases, they do not provide thedecorative appearance of shingle or shake configurations. For instance,composite materials of high or low density polyethylene, (HDPE) and(LDPE) and fibers respectfully, have been taught in U.S. Pat. Nos.5,088,910 and 5,096,046. These teachings require extensive and uncommonequipment to create such synthetic wood products. The problems withwooden shake shingles, in addition to the problem of diminishing forestsupply of cedar shakes, has led to other synthetic materials such ascement, asbestos composition, fiberglass, aluminum, galvanized steel andsophisticated expensive engineered thermoplastics. In many cases,weathering and age of these materials causes them to lose theirsimulated and decorative design concepts and become unsightly anddiscolored. Many commercially available products are paneled designsrepeating the decorative surface over a large area, as for example,4'×8', but still do not provide the simulated decorative effect demandedby home owners and constructions using shakes. One of the negativeaspects of composites is that they fail to exhibit the reinforcingpotential of wood fibers, and/or other fibers, and, in many cases, apoor adhesion between the fibers and the matrix, especially in the useHDPE.

Another facet of the times is the generation of solid and industrialwaste. The creation of the United States Environmental Protection Agency(EPA) is concerned with the continued discarding of waste which iscapable of but has not been recycled. Especially is this so withplastics. Production of plastics in the United States is increasing andis expected to and already has become a considerable part of the wastestream product. The use of recycled plastics as a part of compositematerials is limited largely because of the competition with virginresins and the public misconception that they are inferior if recycled.Beyond the concern of increasing waste plastic products from consumersis the waste from original manufacturers of plastic products. Many ofthese plastics such as PVC, being thermoplastic, can be remeltedrepeatedly. Approximately 40% of PVC produced is directed to pipe andtubing and growing 8% per year.

The term "shake" is commonly used and recognized in the roofing industryfor wooden shake, shingles, slate or tile members.

SUMMARY OF THE INVENTION

It is an object of this invention to provide a composite consisting ofwood fibers and polyvinyl chloride (PVC) plastics and, in particular,recycled PVC and sawdust which offers not only an opportunity to use anabundant waste natural resource in combination with other recycledmaterials as a means to alleviate the ongoing plastic disposal problem.

Another primary object of the invention is to provide an improvedintegrated and simulated shake shingle made up of a composite of PVC andsawdust, and which can be manufactured with commonly available machinerywith minor modifications.

It is a further object of the invention to provide an improved shakeshingle which incorporates sealed interlocking means between adjacentmembers to provide an effective seal between shingles along each course.The PVC for use in this invention can come from many sources includingindustrial scrap, although virgin material may be used or in combinationtherewith. Preferably, the invention proposes the use of commerciallyavailable PVC constructed water or `garden type` hoses from consumer ormanufacturer's waste. An example of such hose is found in U.S. Pat. No.4,306,591. Such vinyl based resins can either be homopolymers,co-polymers or blends of each. Materials that could be used include, butare not limited to, polyethylene, polypropylene, nylon, styrenes, orother engineered or commodity resins. Hose or other materials mayinclude fiber reinforcing such as braided or chopped glass fibers,nylon, carbon/graphite or aromatic polyamide (KEVLAR).

A yet further object of the invention is to provide a shake shingle,being of plastic composite, that is capable of withstanding weatheringand physical abuse from hail without breaking or splintering.

The shake shingles of this invention can be made of varying widths andlengths and textured surfaces in order to provide non-repetitivesimulated shake surfacing. For purposes of this application, "shake"means a product having a simulated appearance of wood, slate, tile orother common or specialty roofing material. The shake can be fastenedusing standard hammers, stapling equipment, and pneumatic nailers andformed with saws and shears as needed to install the roofing.

These and other objects of the invention are realized in a preferredembodiment as described in detail hereinafter.

In a preferred form, the integrated shake member is in the form of aflat rectangular body with its length being greater than its width anddefined by a forward butt end, a head end, a top, a bottom, andlongitudinal first and opposite sides running the length of the shingle.The shingle is preferably molded from a composite of wood sawdust orcellulose and recycled polyvinyl chloride particles, preferablyground-up PVC water hoses. The top of the shingle includes a forwardexposed portion and a rearwood headlap portion with the exposed portionbeing tapered upwardly to said butt end and is molded with a texture tosimulate the appearance of shake shingles or other external roofconstruction. The bottom of the shake has a plurality of ribs laid outin a diamond configuration or other configuration as stiffening ribs.The first longitudinal side is formed of a tenon that terminates shortof the butt end. The second and opposite side includes a mortise toreceive and join with the tenon of an adjacent shingle. Terminating thetenon short of the butt end permits the shakes to be staggered alongeach course without unsightly exposure of the tenon.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of the shake type shingle of this invention.

FIG. 2 is a rear side view.

FIG. 3 is a butt end view of the shake of this invention.

FIG. 4 is a side elevational view of the shake.

FIG. 5 is a schematic of one process for forming the shake.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

While the invention has been described with a certain degree ofparticularity, it is manifest that many changes may be made in thedetails of construction and the arrangement of components withoutdeparting from the spirit and scope of this disclosure. It is understoodthat the invention is not limited to the embodiment set forth herein forpurposes of exemplification, but is to be limited only by the scope ofthe attached claim or claims, including the full range of equivalency towhich each element thereof is entitled.

Referring now to the drawings, the shake type shingle of this inventionis shown generally as 8 being a relatively rectangular member with itslength being greater than its width. For example, a typical simulatedshake would have an overall width of about 13.5" (34 cm), while itslength would be approximately 22" (56 cm). The simulated shake isdefined by a butt end 10 which extends upwardly, and preferably morethan half the length, e.g., 12" (30 cm) in the previous example, to apoint 12 which defines the exposed portion 14 of the shake. Between theend of the exposed portion 14 at 12 and a head end 16 is a headlapportion 18 which is typically of a smooth configuration to receive thenext course of shakes during the construction. The exposed portion ofthe shake is tapered upwardly, being thicker at the butt end 10 whilesmoothly tapering into the headlap portion 18 at the termination of theexposed portion at 12. The exposed portion 14 is molded with a ridgedconfiguration as shown in FIG. 3 to provide the appearance of a woodsplit shake shingle or other specialty roofing product, i.e., slate,tile, etc. The thickness at the butt end 10 may, of course, vary buttypically 3/8 " (10 mm) thick is sufficient. Along the firstlongitudinal side of the shake is a tenon member 20 which extends alongthe length of the shake and terminating at 22 above the butt end 10. Theprovision of having the tenon terminate at 22 will allow, during theplacement of a course of shakes, to be varied longitudinally withrespect to adjacent shakes and thereby duplicate a random pattern asused with wooden shakes. On the other longitudinal side of the shake isa mortise or groove 24 formed to receive and interlock with the tenon ofthe adjacent shingle during placement on the roof. The shake in thepreferred embodiment is primarily flat. By this it is meant that theshake is nearly flat with having raised portions in order to simulatewood or other roofing product (i.e. slate, barrel tile, etc.).

Referring now to FIG. 2, the backside of the simulated shake may includea plurality of reinforcing ribs 30 which are interconnected forming adiamond pattern as shown herein. Although this is not to be restrictiveas any form of ribbing may be utilized to provide strength to the shake.

The shake is preferably composed of ground moldable polyvinyl chloride(PVC) as the matrix along with finely ground wood fiber or sawdust towhich has been added ultraviolet protectants, colorants, and flameretardants. Wood based cellulose fiber may also be used instead of or inaddition to ground wood fiber. The addition of the finely ground woodfiber or sawdust to the ground moldable PVC is performed in a singlecompounded step.

Although many forms of polyvinyl chloride, homopolymers, and co-polymersor blends are capable of use within the broad concepts of the invention,it has been found that recycled PVC hose or tubing such as is soldcommercially for domestic use, i.e., "garden hose" is particularlyapplicable and preferable. Waste from one manufacturer alone representsupwards of several hundred thousand pounds of unusable hose per monthand comes in a variety of sizes, lengths, and color combinations,preferably, the PVC useful in this invention is of a Shore A 60 to 100durometers in hardness. In many instances, such water hose constructionincludes a reinforcing strand which in many cases is formed of fiberbundles of yarns, or other textile composed of filaments of glassfibers, polyester, rayon, aramid, polyamide (Nylon) or otherreinforcement materials. The reinforcement may be in the form of braid,knit, spiral, wrap or the like and have been found to enhance the shakeproduct.

Examples of other types of materials suitable for use within theconcepts of the invention include, but are not limited to, polyethylene,polypropylene, nylon, styrenes, or other engineered or commodity resins,or polymeric materials.

Referring now to FIG. 5, the PVC material 40 is first ground to a sizeto pass through a 3/8" (10 mm) screen size.

The wood fibers 42 for use in the invention may be of hard and/or softwoods which are finely ground, typically scrap sawdust from a wood millor the like which is already finely ground or at least of the sizecapable of passing through a 3/8" (10 mm) mesh screen. Additionally,wood based cellulose fiber may be used. In many instances, the woodparticles will have existing moisture content which may range of 40% to60% humidity.

Preferably, the ground up PVC 40 and wood particles 42 are then causedto pass into a mixer 44 of any type known in the art wherein ultraviolet(UV) inhibitors, flame retardant powders and colorant is added.

The flame retardant powder can be any of a variety or combinations fromthe group of Antimony Trioxide; Tribromophenoxy/Antimony Trioxide--3:1ratio; Decabromodephenyl Oxide/Antimony Trioxide--3:1 ratio; AluminaTrihydrate; Boric Acid; Boric Acid 5 mole; Borax; and Zinc Borate. Theretardants are effective within concentrations between 2% to 10% of thePVC.

The ultraviolet (UV) inhibitor may be mixtures of several types toprotect not only the color of the resulting shake shingle but alsoprotect the deterioration of the other particles within the mixturewhich may vary depending upon the make-up of the PVC. Typical andpreferable UV powders are those sold by CIBA GIGY under the markCHIMASSORB and TINUVIN 328. Both are powders and in a typical exampleare mixed in amounts of 0.5 to 0.7 percent of PVC of CHIMASSORB and 0.3to 0.5 percent by weight of PVC of TINUVIN 328.

The colorant added to the mixing stage may vary as a function of thecolor of the resulting ground PVC material. The overall purpose being toobtain as a resulting mixture a shake which has all of the appearancesof a wood shake or that has an appearance of other desired roofingproducts, i.e., slate, tile, etc. Because PVC hose comes in a variety ofcolors, e.g., clear, green, red, white and combinations, the colorantadded in the mixing stage must compensate for these colors to achievethe desired result of a shake that simulates a wood shake or otherdesired appearance. In one example, the colorant is added on the basisof a 4:1 let-down ratio, i.e., 4 pounds of colorant per 100 pounds ofPVC. Typically, the colorant comes in the form of a powder which havebeen encapsulated in PVC.

The composite mixture in powder form is then submitted to an extruder46, typically of the type manufactured by Akron as their Model 37524HXT,or those described in Modern Plastics Encyclopedia, 1989, pp. 7-9. Inthe operation of the extruder temperatures of the heated barrel andscrew therein may reach between the range of 350° to 450° fahrenheit.The resulting melting and mixing of the composites from the heat,friction and compression forces the material through a die at the headend. However, the time of flight of the composite material therethroughis maintained short enough that it is incapable of melting the fibers,e.g., nylon fibers, found in the PVC hose. As a result, those fibers actas additional filler for strengthening the final resulting product. Inaddition, it has been found the extruder removes moisture from thesystem, particularly from the wood particles and, thus, further enhancesand strengthens the bonding characteristic of the resulting product.

From the extruder 46, the material is then caused to pass to apellitizer 48 which then creates the mixture into particles of 1/4" to3/8" (7-10 mm) or as otherwise sized for use in injection moldingmachine 50.

The injection molding machine is of an reciprocating/screw type, onesuch as manufactured by Lombard, being rated at 500 Ton (450 m.ton).

In accordance with the above-described process steps, the followingexample is set forth below to illustrate the specific process, startingmaterials, processing parameters and blends of PVC and sawdustmaterials.

EXAMPLE

20 lbs. (9 k) of PVC water hose ground smaller than 3/8" (10 mm) ismixed with 8.5 lbs. (3.8 k) of wood sawdust, also smaller than 3/8" (10mm). The UV protectants CHEMSORB 944 FD in an amount of 0.06 lbs. (0.027k) an 0.14 lbs. (0.036 k) of TINUVIN 328 are added to the mixer. Also 1lb. (0.45 k) of a fire retardant Decabromdephnyl Oxide from Great LakesChemical, Inc. and 0.33 lbs. of Antimony Trioxide from Laurel Industriesis added along with 1 lb. (0.45 k) of a colorant. The resultant mixtureis then passed to the remaining process steps as shown in FIG. 5.

Although the invention has been described specifically to shakeshingles, the process and compositions herein are also applicable toother synthetic building materials, including simulated wood buildingmaterials and other simulated roofing products, i.e., slate, tile, etc.

What is claimed is:
 1. An artificial shake shingle to be used on apitched roof, being primarily flat and rectangular with its length beinggreater than its width and defined by a butt end, a head end, a firstside, an opposite second side, a top and a bottom, wherein theimprovement comprises: the shingle comprised of fiber reinforcedpolymeric material whereby a single compounded step is used to create ahomogeneous mixture.
 2. The artificial shake shingle of claim 1, whereinthe fiber reinforced polymeric material is fiber reinforced polyvinylchloride (PVC) material.
 3. The artificial shake shingle of 2, whereinthe fiber reinforced polyvinyl chloride (PVC) is recycled fiberreinforced polyvinyl chloride.
 4. The artificial shake shingle of claim1, wherein the improvement further comprises: the first side having atenon, and the second side having a mortise to receive and join with atenon of an adjacent shingle.
 5. The artificial shake shingle of claim4, wherein the shingle further comprises: wood fiber, to create asimulated roofing or wood product.
 6. The artificial shake shingle ofclaim 5, wherein the shingle further comprises: UV protectant, and acolorant to offset the original color of the PVC to create a simulatedroofing or wood product.
 7. An artificial shake shingle to be used on apitched roof, being primarily flat and rectangular with its length beinggreater than its width and defined by a butt end, a head end, a firstside, an opposite second side, a top and a bottom, wherein theimprovement comprises:the shingle comprised of fiber reinforcedpolymeric material whereby a single compounded step is used to create ahomogeneous mixture, the first side having a tenon, and the second sidehaving a mortise to receive and join with a tenon of an adjacentshingle.
 8. The artificial shake shingle of claim 7, wherein the fiberreinforced polymeric material is fiber reinforced polyvinyl chloride(PVC) material.
 9. The artificial shake shingle of 8, wherein the fiberreinforced polyvinyl chloride (PVC) is recycled fiber reinforcedpolyvinyl chloride.
 10. The artificial shake shingle of claim 9, whereinthe shingle further comprises: wood fiber, to create a simulated roofingor wood product.
 11. The artificial shake shingle of claim 10, whereinthe shingle further comprises: UV protectant, and a colorant to offsetthe original color of the PVC to create a simulated roofing or woodproduct.